张家港市张运机械制造有限公司 Zhangjiagang City Zhangyun Machinery Manufacturing Co.,Ltd. ZY76 (Enlarged to 114) HF Welded Pipe Mill Solution

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1 ZY76 (Enlarged to 114) HF Welded Pipe Mill Solution (Φ25.4~Φ114mm x 1.2~4.0mm x 4~10m x 30~80 m/min) To: Zehtabchiyan From: 1 / 11

2 I Summary 张家港市张运机械制造有限公司 This high-frequency welding pipe mill is specialized equipment to produce high frequency straight seam welded pipes for structural pipe and industrial pipe with Φ25.4mm~Φ114mm and wall thickness of 1.2~4.0mm. Through optimization design, best materials choice, and accurately fabrication and rolls, the whole line can be reached high precision and high speed. Within suitable range of pipe diameter and wall thickness, pipe production speed can be adjusted. II General technical specification 1. Raw material requirements Material: Hot rolling or cold rolling steel Tensile strength: σb 600Mpa Yield point: σs 315MPa Coil width: 80~360mm Coil outer diameter: Max. Φ1600mm Coil inner diameter: Φ508mm Coil weight: Max.3T Material thickness: 1.2~4.0mm for Round pipes / 3.5mm for Square & rectangle pipes 2. Output product scope Pipe type: Straight seam high frequency welded pipes Pipe purpose: Electric heating tube, fridge pipe, Auto car pipe, sporting facility tube, furniture pipe, cooler pipe, pressure feeding pipe, construction pipe, configuration pipe. Round pipe size: Φ25.4mm~Φ114mm * 1.2mm~4.0mm Square pipe size: 20 20mm~90 90mm * 1.2mm~3.5mm Rectangle pipe size: 15 25mm~60 120mm * 1.2mm~3.5mm (a:b 2:1) Producing length: 4~10m (can be designed by customer request) Cutting length precision: ±3mm 3. Line capability Line direction: Pending and will be decided by Buyer Producing speed: 30~80m/min 2 / 11

3 4. Scope of supply 4.1. Technology process Uncoiling Accumulating Leveling Forming HF welding Deburring (outer) Cooling Sizing Straightening Cutting Discharging 4.2. Parts of Line Double heads Decoiler set Shear & butt welding device set Horizontal accumulator set Forming & Sizing unit set Hot saw set Run out table (single side discharging) set Control system set Roller Optional / prepared by Buyer Pneumatic system prepared by Buyer IV Main structure 1. Double heads Decoiler (Hydraulic type) Configuration: Two drums expanding by hydraulic Coil inner dia.: Φ508mm Coil outer dia.: Φ1600mm Material width: 80~360mm Coil weight: 3T Braking type: Two phase braking by pneumatic Drums exchanging: 180 turning by hand 3 / 11

4 2. Automatic shearing & butt welding (Hydraulic shear) 2.1. Shearing method: Type: Hydraulic shearing Pneumatic system: 0.4~0.7Mpa Adjustable range: Φ120 Cutter blade: 1 pair Material of blade: Cr12 (HRC58~62) Strip width: 100~280mm Strip thickness: 1.2~4.0mm 2.2. Automatic Argon Arc welding Type: PLC control, Frequency controlled TIG automatic welding Welder: TIG Welder current: 22~315A Protection gas: Argon whose purity over 99.99% Welding gun: 1 set Clamping: Pneumatic Welding time: 75~350mm/min 2.3. Outer size: 1100 x 1100 x 1650mm 3. Horizontal accumulator Accumulator: introduce peripherally and feeding from center Out diameter: 4.5m Width of metal strip: 80~360mm Thinness of metal strip: 1.2~4.0mm Feeding speed: 150m/min Configuration: Turning frame, Pinch machine (11kw AC motor), Main body (15kw AC motor) Feeding control: Feeding is manual control which same as Uncoiler; Discharge is non-power style. 4 / 11

5 4. Forming & Sizing unit 4.1. Forming & Sizing Parts of Forming & Sizing: Driving system set Second grade transmission sets Feeding & Leveling device set Horizontal roll frame sets Vertical roll frame sets 5 / 11

6 Driving system Forming & Sizing driving system: 2 sets Motor type: Z Kw/1500rpm Reducer type: ZLY hard gear reducer Motor driving system: Control by DC digital converter Second grade transmission Transmission type: Gear box and gimbaled joint Gearbox configuration: Spiral bevel gear & cylindrical helical gear Lubricating: Gear oil soaking Oil level display: Inspection glass on box Quantity Spiral bevel gear Gear box Forming unit 7 20CrMnTi HT200 Sizing unit 6 20CrMnTi HT Horizontal roll frame & Vertical roll frame Forming height: Φ160mm Adjusting of Horizontal roller: Manual (or manual sync adjustment) Adjusting of Vertical roller: Manual sync screw adjusting Name Section Quantity Shaft dia. Material Treatment Horizontal Forming unit 7 Φ80mm 42CrMo HF quenching roll frame Sizing unit 6 Φ80mm 42CrMo HF quenching 6 / 11

7 Name Section Quantity Shaft dia. Material Treatment Vertical roll frame Forming unit 7 Φ50mm 40Cr HF quenching Sizing unit 6 Φ50mm 40Cr HF quenching 4.2. Welding Parts of Welding: Guiding frame set Welding pinch frame set HF welder set (or prepared by Buyer) Deburring cutter (Pneumatic) set Welding pinch frame Type: 3 rollers pinch Shaft diameter: Φ50mm Material of shaft: 40Cr (HF quenching) Adjusting: Manual screw adjusting Deburring cutter Type: Two cutters setting Feed/retract: Pneumatic adjusting Cutter adjustment: Manual screw adjusting High frequency welder: Type: High frequency influence welding Size: GGP HC Power: 300Kw 4.3. Cooling Cooling way: Spray and soaking Length of cooling: 4000mm 4.4. Speed supervising device Type: Two roller type with pneumatic clamping Quantity: 1 set 7 / 11

8 Outer dia. of roller: Φ111.4mm Material of roller: Cr Turkey head straightening device Type: Single face and with 4 rollers Configuration: Turning adjusting from top, bottom, left and right Adjusting method: Manual screw adjustment Shaft material: 40Cr (HF quenching) Quantity: 2 sets 5. Hot frication computer saw Type: CPU controlling saw Application: 1) Supervise and fix the product length, quickly start to match with pipe mill 2) Keep the saw moving synchronously with pipe mill while cutting 3) Return quickly Control method: CPU Controller-> Motor-> Reducer-> Gear & rack-> Saw car motion Cutting method: Hot frication cutting Max running speed: 80m/min Applicable pipe size: Φ25.4~Φ114mm Applicable pipe thickness: 4.0mm Cutting length precision: ±3mm Saw blade size: Φ600/Φ Saw blade speed: 3400rpm Blade turning motor: 22Kw 8 / 11

9 Tracking motor: 22Kw Pneumatic system: 0.4~0.7Mpa 6. Run out table (single side discharging) Configuration: Frame type Length: 15m Discharging speed: 130m/min Driving motor: AC3Kw 9 / 11

10 7. Shearing device (Hydraulic) Shearing method: Hydraulic cutting Hydraulic system: AC 3.0KW 10Mpa Cutter blade: 1 pair Material of blade: Cr12 (HRC58~62) Strip width: 80~360mm Strip thickness: 1.2~4.0mm Welder: Prepared by Buyer 8. Roller (Optional or prepared by Buyer) 7.1. Forming and Sizing rollers Material: Cr12(JIS-SKD1, ASTM-D3) Hardness: Surface quenching HRC 60 ± 2; critically grinding 7.2. Welding roller Material: H13 (JIS-SKD61, ASTM-H13) Hardness: Surface quenching HRC 50 ± 3; critically grinding 9. Brands of main parts NO Parts name Brand Remarks 1 Main driving motor SIMO Xi an 2 Motor driver (DC digital converter) PARKER 3 Bearing HRB, LYC, ZWZ 4 Pneumatic element AIR TAC V Foundation and advised Buyer s necessary Site area of machine (length X Width): 62m 7m Site area of cabinets (length X Width): 6m 3m 10 / 11

11 Machine foundation base: See foundation drawing CAD Overhead crane: 2 sets of 5 Ton overhead crane Magnetic bar (impeder core): prepared by Buyer Saw blade: Prepared by Buyer Lubricating oil grease, cooling emulsion and etc will be prepared by Buyer One set of Emulsion water cooling pool (Volume 30 m3*1pools)for pipe-welding mill and plate exchanger of HF-welder, with two sets of pumps(ac4kw lift 30m & flux 30m3/hour), water pressure meter,valves,and water pipes will be prepared by Buyer. Or use one set of glass fiber cooling tower for Emulsion water cooling pool and plate exchanger of HF-welder. Adopting ground or attic frame and room of high-frequency welder for machine unit, stack basket for welded pipe, made by buyer. The cables which from power station to pipe mill line, and cables & wires between machines and cabinets, all of them will be prepared by Buyer. One set of 1m3 /min air compressor and one set 0.50m3 air tank, 0.7~1.0Mpa. Whole of the pneumatic supply system will be prepared by Buyer. Lifts tools anchor bolts expand bolts embedded and fixing materials for installing machine will be prepared by Buyer. Power supply: High frequency welder power: GP-300Kw Power of supply: 3P/4W/380V/50Hz Total power of Line: 650Kw VI Additional options Worm Wheel adjusting Configuration: Worm and worm wheel Function: To make the inner block and outer block move at same time while adjusting. Display: Number display. 11 / 11